阅读说明：本技术 带电阻器的电刷式开关及其制造方法 (Brush type switch with resistor and manufacturing method thereof ) 是由 宫田致良 中山尚也 于 2019-06-26 设计创作，主要内容包括：本发明提供一种带电阻器的电刷式开关以及其制造方法,其能够使生产性大幅度提高。本发明的带电阻器的电刷式开关具备壳体、固定于壳体的固定触点图案、能够倾倒地支承于壳体的杆件、以及通过杆件的动作与固定触点图案连接的可动触点电刷,固定触点图案具有分离地配置于壳体内的多个固定触点、与多个固定触点分别连接的多个端子,可动触点电刷具有与多个固定触点分别分离或接触的多个触点弹簧片、以及安装于触点弹簧片之间以及触点弹簧片之间的电阻值不同的多个电阻器。(The invention provides a brush switch with a resistor and a manufacturing method thereof, which can greatly improve the productivity. The brush switch with a resistor includes a case, a fixed contact pattern fixed to the case, a lever supported to be tiltable in the case, and a movable contact brush connected to the fixed contact pattern by an operation of the lever, the fixed contact pattern having a plurality of fixed contacts disposed separately in the case and a plurality of terminals connected to the plurality of fixed contacts, respectively, the movable contact brush having a plurality of contact spring pieces separated from or brought into contact with the plurality of fixed contacts, respectively, and a plurality of resistors having different resistance values attached between the contact spring pieces and between the contact spring pieces.)

1. A brush switch with a resistor, comprising:

a housing;

a fixed contact pattern fixed to the housing;

a lever supported to be tiltable in the housing; and

a movable contact brush connected with the fixed contact pattern by the action of the lever,

the fixed contact pattern has:

a plurality of fixed contacts separately disposed in the housing; and

a plurality of terminals connected to the plurality of fixed contacts, respectively,

the movable contact brush includes:

a plurality of contact spring pieces that are separated from the plurality of fixed contacts, respectively, or are in contact with the plurality of fixed contacts, respectively; and

and a plurality of resistors having different resistance values, which are mounted between the plurality of contact spring pieces.

2. The brush switch with resistor according to claim 1,

the plurality of resistors are members obtained by mounting and soldering chip resistors in a mold frame that isolates the plurality of contact spring pieces from each other.

3. The brush switch with resistor according to claim 2,

the movable contact brush is integrated by fitting the mold frame into the recess fixed to the rod.

4. A method for manufacturing an electric brush switch with a resistor, characterized by comprising the following steps:

a step of press-forming a movable contact pattern including a plurality of contact spring pieces on one metal plate;

a step of performing plating treatment on the movable contact pattern after press forming;

a step of precisely molding a resin mold frame on the movable contact pattern after the plating treatment;

a step of mounting and welding a chip resistor in the precisely formed mold frame;

cutting the movable contact pattern welded with the chip resistor into a plurality of contact spring pieces and bending the contact spring pieces so as to punch and form a movable contact electric brush;

a step of integrating the molded movable contact brush by fitting the mold frame into the recess fixed to the rod; and

and assembling the integrated rod piece with the movable contact brush into a shell with a fixed contact pattern in an insert molding mode.

Technical Field

The present invention provides a brush switch with a resistor used as a detection switch of an Electronic Control Unit (ECU) circuit (hereinafter referred to as an ECU circuit) for a vehicle and a manufacturing method thereof.

Background

Conventionally, as such a switch used in an ECU circuit, a switch device described in patent document 1 below is known. The switching device is a switch as follows: at least two of the common fixed contact, the first switching fixed contact, and the second switching fixed contact are extended in the housing above the holding member to form an extended portion, and a resistor is mounted on a mounting portion formed in a part of the extended portion.

Disclosure of Invention

Technical problem

However, according to the switching device of patent document 1, the mounting method of the resistor is as follows: a support wall portion is erected above the holding member, a recess is provided in an extending portion held by the support wall portion, and the chip resistor is housed in the recess and soldered. However, since the recess for housing the chip resistor is provided on the side surface of the support wall portion having a complicated shape, it is not suitable for soldering in a surface mounting apparatus which automatically conveys the chip resistor by a solder printer, a chip mounter, a reverberatory furnace, or the like. Therefore, since a process of welding the resistor by one manual operation is required, there are problems as follows: cannot be mass-produced and results in a significant increase in manufacturing costs.

Accordingly, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a brush switch with a resistor and a method for manufacturing the same, which can greatly improve productivity.

Technical scheme

In order to achieve the above object, a brush switch with a resistor according to the present invention includes: a housing; a fixed contact pattern fixed to the housing; a lever supported to be tiltable in the housing; and a movable contact brush connected to the fixed contact pattern by operation of the lever, the fixed contact pattern including: a plurality of fixed contacts separately disposed in the housing; and a plurality of terminals connected to the plurality of fixed contacts, respectively, the movable contact brush having: a plurality of contact spring pieces that are separated from the plurality of fixed contacts, respectively, or are in contact with the plurality of fixed contacts, respectively; and a plurality of resistors having different resistance values and mounted between the plurality of contact spring pieces.

In the brush switch with a resistor according to the present invention, the plurality of resistors may be mounted on a mold frame for separating the plurality of contact spring pieces from each other, and the chip resistor may be soldered to the mold frame.

In the brush switch with a resistor according to the present invention, the movable contact brush may be integrated by fitting the mold frame into a recess fixed to the rod.

Further, a method for manufacturing a brush switch with a resistor according to the present invention is characterized by comprising the steps of: a step of press-forming a movable contact pattern including a plurality of contact spring pieces on one metal plate; a step of performing plating treatment on the movable contact pattern after press forming; a step of precisely molding a resin mold frame on the movable contact pattern after the plating treatment; a step of mounting and welding a chip resistor in the precisely formed mold frame; cutting a plurality of contact spring pieces on the movable contact pattern welded with the chip resistor, bending the contact spring pieces, and punching and forming a movable contact electric brush; a step of integrating the molded movable contact brush by fitting the mold frame into the recess fixed to the rod; and a step of assembling the integrated rod member with the movable contact brush to a housing in which a fixed contact pattern is insert-molded.

Technical effects

According to the present invention, a mold frame is precisely molded on a movable contact pattern formed of one metal plate constituting a movable contact brush, and a chip resistor is mounted and welded in the mold frame, whereby a switch having the resistor mounted on the movable contact brush can be manufactured. Therefore, the following effects are provided: since the resistors can be mounted on the plurality of movable contact patterns using the surface mount device of the automatic transfer, the production efficiency can be greatly improved, and the manufacturing cost can be greatly reduced by mass production.

Drawings

Fig. 1 (a) is a perspective view showing an external appearance of a brush switch with a resistor according to the present invention, fig. 1 (b) is a front view of the switch, fig. 1 (c) is a plan view of the switch, and fig. 1(d) is a circuit configuration diagram of the switch.

Fig. 2 is an exploded perspective view showing an internal configuration of the electric brush type switch with a resistor according to the present invention.

Fig. 3 (a) is a plan view and fig. 3 (b) is a side view of a fixed contact pattern of the switch.

Fig. 4 (a) is a plan view of the base of the switch, fig. 4 (B) is a sectional view taken along line B-B, fig. 4 (C) is a sectional view taken along line C-C, and fig. 4 (D) is a sectional view taken along line D-D.

Fig. 5 is a front view and a plan view showing a step of press-forming a movable contact pattern in the manufacturing method of the present invention.

Fig. 6 is a front view and a plan view showing a step of performing plating treatment on the movable contact pattern in the manufacturing method of the present invention.

Fig. 7 is a front view and a plan view showing a process of precisely molding a mold frame on a movable contact pattern in the manufacturing method of the present invention.

Fig. 8 is a front view and a plan view showing a step of mounting and bonding a chip resistor in a mold frame in the manufacturing method of the present invention.

Fig. 9 is a front view and a plan view showing a step of cutting a plurality of contact spring pieces out of a movable contact pattern in the manufacturing method of the present invention.

Fig. 10 is a front view and a plan view showing a step of bending a plurality of contact spring pieces in the manufacturing method of the present invention.

Fig. 11 is a front view, a plan view, and a perspective view illustrating a step of fitting and fixing a mold frame of the movable contact brush into a concave portion of a rod to be integrated in the manufacturing method of the present invention.

Fig. 12 is an explanatory view of an operation of the brush switch with a resistor according to the present invention, in which fig. 12 (a) is a sectional view at a free position, fig. 12 (b) is a sectional view at a conducting position, and fig. 12 (c) is a sectional view at a full moving position.

Description of the symbols

SW: brush type switch with resistor

10: shell body

20: base seat

21: bearing assembly

22: clamping claw

30: top cover

31: opening part

32: locking hole

40: fixed contact pattern

41: fixed contact (common fixed contact)

42: fixed contact (first fixed contact)

43: fixed contact (second fixed contact)

44: terminal (Power terminal)

45: terminal (grounding terminal)

46: terminal (first output terminal)

47: terminal (second output terminal)

50: rod piece

51: operation part

52: concave part

53: cam part

54: hole(s)

55: shaft part

60: movable contact brush

61: movable contact pattern

62: contact spring lamination (common contact spring lamination)

63: contact spring lamination (first contact spring lamination)

64: contact spring lamination (second contact spring lamination)

70: resistor with a resistor element

71: chip resistor (first chip resistor)

72: chip resistor (second chip resistor)

73: skin membrane

74: cream solder

80: mould frame

81: a first container part

82: second container part

83: partition wall

84: claw

Detailed Description

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.

As shown in fig. 1 and 2, the brush switch SW with a resistor according to the present invention includes a fixed contact pattern 40, a lever 50, and a movable contact brush 60 in a box-shaped case 10 formed by a base 20 and a top cover 30, and a plurality of resistors 70(71, 72) are attached to the movable contact brush 60 and incorporated in the case 10, thereby stabilizing and reducing the size of a circuit as compared with a switch with an external resistor 70.

The switch SW is used as a detection switch of an ECU circuit for vehicle mounting, and resistors 71(R1) and 72(R2) having different resistance values are mounted, so that outputs in three different modes, that is, a C-a circuit, a C-B circuit, and an a-B circuit, can be obtained in accordance with the operation of the lever 50 as shown in fig. 1(d), and therefore, three different functions can be controlled on the microcomputer side.

Hereinafter, a detailed structure of the brush switch SW with a resistor according to the present invention will be described according to a manufacturing method thereof.

As shown in fig. 3, the fixed contact pattern 40 is a member obtained by press-molding a single conductive metal plate (brass in the present embodiment) with a plurality of fixed contacts arranged thereon. The fixed contact 41 disposed on the right side in the figure is a common fixed contact, and terminals (a power terminal 44 and a ground terminal 45) formed by bending both ends thereof are connected. The fixed contacts 42 and 43 arranged on the left side in the figure are the first fixed contact and the second fixed contact, and terminals (the first output terminal 46 and the second output terminal 47) formed by bending respective end portions are connected. The dotted line in the figure is a predetermined cut line.

As shown in fig. 4, the fixed contact pattern 40 is insert-molded into the base 20, and then the base 20 is formed of an insulating resin material (polyamide resin in the present embodiment) by cutting the dotted line portion with a press machine. Thus, the common fixed contact 41, the first fixed contact 42, and the second fixed contact 43 are arranged in an insulated state on the bottom surface in the base 20, and the power supply terminal 44, the ground terminal 45, the first output terminal 46, and the second output terminal 47 are arranged outside the base 20.

As shown in fig. 5, the movable contact pattern 61 in which the movable contact brush 60 is formed is a press-molded member in which a plurality of contact spring pieces are arranged on a metal plate (phosphor bronze in the present embodiment) having conductivity and excellent elasticity. Here, in the present embodiment, movable contact patterns 61 are arranged in three rows × three columns on one metal plate, and a plurality of cavities are provided in one mold, whereby productivity can be significantly improved. In each movable contact pattern 61, a portion serving as a common contact spring piece 62 is arranged at the center, and portions serving as a first contact spring piece 63 and a second contact spring piece 64 shorter than the common contact spring piece 62 are arranged on both sides thereof.

Next, as shown in fig. 6, a plating process is performed on the movable contact pattern 61. The plating process is a method for improving the wettability of the cream solder 74 described later, and the coating film 73 is formed in a predetermined thickness by silver plating only on the contact spring pieces (the common contact spring piece 62, the first contact spring piece 63, and the second contact spring piece 64) in the movable contact pattern 61.

Next, as shown in fig. 7, a mold frame 80 is precisely molded on the movable contact pattern 61 after the plating process. The mold frame 80 is a member for positioning the mounted resistor 70, and is integrated with the movable contact pattern 61 by precisely molding a metal plate sandwiched by an insulating resin material (polyamide resin in the present embodiment). The installation position of the mold frame 80 is set at the root portion of the contact spring piece, and is divided into a first receiving portion 81 located between the common contact spring piece 62 and the first contact spring piece 63, and a second receiving portion 82 located between the common contact spring piece 62 and the second contact spring piece 64, in accordance with the size of the resistor 70. A partition wall 83 is formed at the center of the mold frame 80 to separate the first receiving portion 81 and the second receiving portion 82.

Next, as shown in fig. 8, the resistor 70 is mounted and welded in the mold frame 80 after the precision molding. In the present embodiment, using an automatic transfer surface mounting apparatus, cream solder 74 is first applied to the inside of the first receiving portion 81 and the second receiving portion 82 of the mold frame 80 by a cream solder printer. Then, two rectangular chip resistors (the first chip resistor 71 and the second chip resistor 72) having different resistance values are mounted in the first receiving portion 81 and the second receiving portion 82, respectively, by a chip mounter. Then, the cream solder 74 is heated and melted by a reverberatory furnace, and the two chip resistors 71, 72 are soldered and fixed above the movable contact pattern 61. Since the mold frame 80 on which the chip resistors 71 and 72 are mounted is provided with the partition wall 83, it is possible to prevent the cream solder 74 from spreading and causing a mounting failure.

Next, as shown in fig. 9, the movable contact pattern 61 to which the chip resistors 71, 72 are bonded is cut into a plurality of contact spring pieces. That is, the common contact spring piece 62, the first contact spring piece 63, and the second contact spring piece 64 are formed separately from the movable contact pattern 61 by cutting the hatched portion in the drawing with a press machine.

Then, as shown in fig. 10, the movable contact brush 60 is press-molded by bending the cut movable contact pattern 61. That is, the common contact spring piece 62, the first contact spring piece 63, and the second contact spring piece 64 are bent into a U shape by bending a portion indicated by an outer fold line in the drawing with a press machine, and the movable contact brush 60 having elastic force is molded.

Next, as shown in fig. 11, the movable contact brush 60 is integrated with the lever 50. The lever 50 is molded from a resin material (polyacetal resin in the present embodiment) having insulation properties and excellent wear resistance, and includes an operation portion 51 that receives an external force, a concave portion 52 that holds the movable contact brush 60, and a cam portion 53 that transmits the external force to the movable contact brush 60. When the mold frame 80 integrated with the movable contact brush 60 is inserted into the concave portion 52 of the lever 50, the claws 84 located on both the left and right sides of the mold frame 80 are fitted into and fixed to the holes 54 located on both the sides of the concave portion 52, and the U-shaped first contact spring piece 63 and the second contact spring piece 64 are held in the concave portion 52 in a power storage state. Thus, the movable contact brush 60 and the lever 50 are connected to each other in one operation, and therefore, the operation at the time of assembly can be simplified.

Finally, the integrated lever 50 with the movable contact brush 60 is accommodated in the case 10. As shown in fig. 2, when a shaft 55 provided on an outer surface of the lever 50 is inserted into the bearing 21 of the base 20, the lever 50 is supported to be tiltable at a predetermined angle with the shaft 55 as a fulcrum. Then, when the top cover 30 is closed from above the base 20 and the locking claws 22 provided on the outer side surface of the base 20 are fitted into the locking holes 32 fixed to the top cover 30, the lever 50 with the movable contact brush 60 to which the resistor 70 is attached is accommodated in the case 10 formed by the base 20 and the top cover 30. As shown in fig. 1, operation portion 51 of lever 50 protrudes from opening 31 provided in the top plate of top cover 30, and brush switch SW with resistor according to the present embodiment is completed.

The brush switch SW with a resistor according to the present embodiment is configured as described above, and in the free position state after rest shown in fig. 12 (a), the common contact spring piece 62 of the movable contact brush 60 is in contact with the common fixed contact 41 on the base 20, but the first contact spring piece 63 and the second contact spring piece 64 are not in contact with the first fixed contact 42 and the second fixed contact 43. Therefore, the common fixed contact 41, the first fixed contact 42, and the second fixed contact 43 are not turned on, and the switch is in an off state.

Here, when an external force acts on the lever 50, the lever 50 rotates about the shaft 55 as a fulcrum and falls, so the operating portion 51 receiving the external force acts as a point of force, and the cam portion 53 in contact with the movable contact brush 60 acts as a point of action. At this time, as shown in fig. 12 (b), the movable contact brush 60 is pushed down to the cam portion 53 to start compression, and as shown in fig. 12 (c), the operating portion 51 of the lever 50 is pushed into the housing 10 at the full-shift position, and the first contact spring piece 63 and the second contact spring piece 64 are in contact with the first fixed contact 42 and the second fixed contact 43, respectively. Therefore, the common fixed contact 41, the first fixed contact 42, and the second fixed contact 43 are turned on, and the switch is switched to the on state.

In addition, referring to fig. 1(d), the first chip resistor 71(R1) and the second chip resistor 72(R2) have different resistance values. Therefore, when the switch is in the on state, outputs of three different values of the C-a circuit (the resistance value of the first chip resistor R1), the C-B circuit (the resistance value of the second chip resistor R2), and the a-B circuit (the sum of the resistance value of the first chip resistor R1 and the resistance value of the second chip resistor R2) are obtained. Therefore, three different functions can be controlled on the microcomputer side of the ECU circuit that reads the output.

When the external force applied to the lever 50 is released, the lever 50, which has fallen, is raised by the elastic restoring force of the movable contact brush 60. As a result, the movable contact brush 60 returns to the original state, the first contact spring piece 63 and the second contact spring piece 64 are separated from the first fixed contact 42 and the second fixed contact 43 again, the conduction between the common fixed contact 41, the first fixed contact 42, and the second fixed contact 43 is cut off, and the switch is switched to the off state.

As described above, according to the brush switch SW with a resistor of the present embodiment, the two resistors 71 and 72 are mounted on the movable contact brush 60 and are incorporated in the housing 10, so that the process of mounting the external resistor can be eliminated, and the circuit can be stabilized and downsized compared to the switch with the external resistor. In addition, since the resistors 71 and 72 can be welded at the stage of the movable contact pattern 61, it is possible to prevent assembly failure and improve productivity, and the assembly process can be simplified by integrating the movable contact brush 60 with the lever 50.

In the above embodiment, although the movable contact patterns 61 formed of one metal plate are provided in plural numbers of three rows × three columns, the number of rows or columns may be increased as appropriate in consideration of production efficiency. In the movable contact brush 60, the number of contact spring pieces is three, and two resistors 71 and 72 are mounted, but the number of contact spring pieces and/or the number of resistors can be increased to accommodate a variety of detection circuits.